Mounting system for supporting objects

ABSTRACT

A new mounting system for elevating and supporting objects such as solar panels and satellite dishes either upon a roof or above ground.  
     The mounting system utilizes extruded aluminum horizontal members and a means to secure an object upon the horizontal members. This means to secure is an end clamp having a lip for gripping and either having a heeled distal end or one that instead of incorporating a heel, uses a wedge or half-moon washer to perform the same function. The heel, positioned above the horizontal member prevents the end clamp from rotating as it is screwed into frictional engagement with the member. Such rotation is undesirable since it would reduce the area of the lip in gripping contact with an adjacent object.

CLAIM OF PRIORITY

[0001] This is a continuation-in-part application that claims thebenefit of U.S. patent application bearing Ser. No. 09/758,407 filedJan. 10, 2001 which claimed priority to U.S. Provisional Applicationbearing serial No. 60/176,126 filed Jan. 14, 2000.

BACKGROUND OF INVENTION

[0002] The present invention relates to the building industry andspecifically to mounting equipment and a method for supporting an objectover a roof or above ground.

[0003] Mounting equipment or sometimes referred to herein as a mountingsystem, is used to attach objects such as solar panels includingphotovoltaic (PV) modules and solar pool heating panels, solar heatingcollectors (referred to sometimes as domestic hot water collectors),satellite dishes, air conditioning units, etc. The mounting equipment istypically fastened at its base end to either a foundation, directly tothe earth, or to support structures on a building such as roof rafters.

[0004] The roofs of building structures have been used for placement ofobjects with the primary reason for location upon a roof is the lack ofalternative space.

[0005] Air conditioning units, because of their relative heavy weight,provide a downward force upon the roof in any weather condition.However, a problem exists for other objects such as satellite dishes andsolar panels, which can, in certain windy conditions, be lifted off themounting equipment to which they are attached because the force of thewind applied against the surface area on the side or underside of theobject creates an uplift condition which is greater than the attachmentstrength of the mounting equipment.

[0006] Besides the need for compliance with governmental building coderequirements, a more time efficient method for installing a mountingsystem, particularly to a roof, is highly desired by installers. Afaster installation reduces the labor costs associated with eachinstall.

[0007] One of the problems with present installations is the fact thatmore than one lag bolt or other type of fastening bolt is required foreach mounting plate that is fastened to the roof. The risk is high thatsome of the lag bolts will drill at an angle other than perpendicular tothe roof rafter. The severity of the angle and the trajectory of the lagbolt penetration into the rafter could cause the rafter to split;further reducing the structural integrity of the mounting system.

[0008] For many years, existing solar mounting systems were installedusing a threaded pipe nipple that screwed into a mounting plate commonlycalled a “floor flange” in the trade. The threaded floor flange has beencommercially available as a standard plumbing item for many years. U.S.Pat. No. 5,603,187 issued to Merrin et al. is typical of the prior art.

[0009] The Merrin design, as well as similar prior art, have a commondesign limitation. They require multiple bolts be installed offset fromthe threaded vertical support flange or stanchion. Also, because of thefloor flange design, it would not permit industry standard flashing toinstall flat on the roof; primarily due to the base flashingcircumference interfering with the height of the floor flange.

[0010] A mounting system based upon the Merrin patent, while appropriatefor roof mounting of heavy objects such as air conditioners, is notpractical for use with lighter objects such as solar panels or satellitedishes. The Merrin design precludes direct (bolted) attachment to theroof rafter by each of the mounting holes present on the base plate;primarily due to the width of the rafter in relation to the spacing ofthe mounting holes. Further, Merrin views rafter attachment as alimitation and therefore teaches away from using rafters for structuralsupport. Therefore, Merrin teaches attachment to the roof decking whichgenerally consists of only ½″ plywood or a composite sheeting; either ofwhich do not provide the strength of a bolt mounted to a rafter in anuplift condition.

SUMMARY OF INVENTION

[0011] The disclosure contained in U.S. Pat. No. ______ is incorporatedherein by reference.

[0012] This invention presents a mounting system for supporting objectssuch as solar panels and satellite dishes. Also claimed is an end clampthat provides superior frictional engagement of the object to themounting equipment.

[0013] Definitions

[0014] Alignment Means—a means to align a roof mount such as a guidetunnel.

[0015] Fastening Means—a means to fasten the base mount portion of themounting equipment to a roof rafter, or ground racking system.

[0016] Support Means—a term used to collectively refer to the variousparts necessary to support an object. Support means includes one or morehorizontal members upon which the weight of an object will be supported,and clamps to secure the object to the horizontal member(s).

[0017] Attachment Means—Means by which the support means is attached tothe base mount. One example is by the use of a bolt threadably engaginga stanchion located on the opposite side of a horizontal member. Thebase portion of the stanchion is threaded into the base mount.

[0018] Securing Means—Means to secure the object upon the horizontalmember(s). The securing means comprises either a pair of end clamps eachhaving a raised distal heel, or a wedge or half-moon washer andsubstitute for a heel and used with end clamps having no heel. Thesecuring means is secured to the adjacent horizontal member and, astightened, it frictionally engages a portion of the object to maintainit in a secure position upon the horizontal member.

[0019] The mounting equipment comprises at least one base mount andassociated support clamps and support rails, and are not limited to rooftop installations. They can be installed over pipe supports or attachedto other support systems or ground racking systems. Types of groundracking systems include, but are not limited to pipe supports, polemounted installations, building facades and patio covers.

[0020] First Example

[0021] By way of a first example, for new construction or reroofing, aroof mount would be attached prior to installation of the roof flashing.The component parts for supporting a solar panel or satellite dish wouldbe assembled and attached to the roof mount over the flashing. Featuresof the invention are as follows:

[0022] 1. a new base mount (also referred to as a roof mount) having athreadable elongated member or stanchion which requires a single lagbolt positioned directly beneath the stanchion for fastening to a roofrafter. A guide tunnel is also provided on the roof mount for properdrill angle into the rafter.

[0023] 2. A support design comprising either a composite or aluminumextruded horizontal members and associated equipment for attachment to aplurality of roof mounts which will support a mounted object such as asolar panel. Although a particular C-shaped design is depicted in thedrawings, any design to facilitate the securing means is considered tobe part of the support design. The purpose of the horizontal members isto provide: 1) support for the weight of an object positioned upon themember; and, 2) to facilitate the securing means of the object to themember by the use of a pair of end clamps for each member used.

[0024] 3. A securing means for securing the end of a supporting objectto the support design. One example of the securing means is a pair ofcooperating end clamps each having a raised heel which enhancesfrictional engagement when being secured into position upon a horizontalmember with an object to be secured therebetween.

[0025] Second Example

[0026] In a second example, the mounting system, instead of beingfastened to a new roof rafter for support, is operatively fastenedeither: a) upon existing roofs or framework; or, b) over pipe supportsor other support systems not necessarily located upon a roof. Here, theroof mount referred to earlier is not utilized although the otherfeatures described in paragraphs 2, 3, and 4 above pertain. For thisexample, the roof mount is replaced as the means to fasten the mountingsystem with an alternative means such as that described in U.S. Pat. No.5,746,029 issued to Ullman and which is herein incorporated byreference.

[0027] Roof Mount (For Example 1)

[0028] In order to utilize my mounting system, a roof mount must firstbe fastened to a rafter. The roof mount can be manufactured from anymaterial commonly used in the building trade to support objects upon aroof. Preferably, the mount is machined from aluminum and comprises athreaded cavity with an insertion opening for threadably receiving avertical stanchion. Directly below the cavity is an aperture forinsertion of a lag bolt for attachment to the rafter. This is a uniquefeature of my support base. Only one lag bolt or other type of fasteningbolt is required. For a one bolt design, having the attachment forcepositioned directly beneath the stanchion provides the highest level ofattachment strength.

[0029] Additionally, a special hollow can be machined at the base of thechannel to allow clearance for the bolt head when installed so that itdoes not contact the bottom surface area of the stanchion. This permitsmaximum threadable engagement of the stanchion to the base.

[0030] The base section of the roof mount comprises a base for directcontact with the decking surface of a roof and a vertically extendingcylindrical member having the threaded cavity and an offset wall havinga guide tunnel. It is not necessary that, the guide tunnel be part ofthe cylindrical member. It is however, preferable to maintain a minimumdistance between channel and guide tunnel so that it is easy to use theguide tunnel to drill a pilot hole into a rafter and to thereafter alignthe pilot hole with the aperture by sliding the base section a minimaldistance.

[0031] The distance between the cavity and guide tunnel however, must besufficient so as not to compromise the overall structural integrity ofthe base section.

[0032] In an alternative design, the guide tunnel is not used and theroof mount base section simply incorporates my single bolt designdescribed above which includes a base and a vertically extendingcylindrical member having the threaded cavity.

[0033] The base can be of any geometrical shape such as circular,rectangle or square. All that is required is that the geometrical shapebe sized accordingly so that it does not interfere with the alignment oruse of commercially available flashing to the roof.

[0034] Once the lag bolt is fastened to the rafter, one end of thestanchion is screwed into the threaded cavity and the roof flashing isthereafter installed. For purposes of this specification, the basesection and the stanchion/elongated member are collectively referred toas the roof mount. Although the mounting equipment may be installed dayslater, it is preferable to install the roof mount at this point.

[0035] Installation of Mounting System Upon Support Means

[0036] At least one horizontal member is provided as a means forsupporting an object. The number of horizontal members used will bedependent upon the type of object to be supported.

[0037] The horizontal member is preferably made from extruded aluminumand can be manufactured to any length. Each horizontal member has atrack that can be used by either T-nuts or slidable inserts which havebeen designed to fit within and slide along this track.

[0038] The T-nut has a threaded stem facing upward for engaging a clampwith a nut.

[0039] The slidable inserts can be designed to have: 1) a hole forallowing the threaded stem of a screw or the like to pass upwards whilethe headed end of the screw can not; or, 2) a female threaded hole forcooperative securement with the clamps as will be discussed now.

[0040] Clamps are used to grip an edge portion of an adjacent object andsecure that object in position once the clamp has been fastened to theadjacent horizontal member. The gripping end of the clamp can have asurface which is flat or serrated. One clamp is provided for eachslidable insert or T-nut. The clamp has a hole or aperture and ispositioned so that either a fastening bolt can be inserted through andsecured to the threaded hole of the threadable insert, or it can besecured to the upward facing threaded T-nut stem or, a threaded stem ofsufficient length extends upwards through the aperture in the slidableinsert and through the aperture in the clamp. Thereafter, a nut is usedto threadably engage the threaded stem and fasten the clamp to thehorizontal member.

[0041] There are two types of clamps available: end clamps and bi-moduleclamps.

[0042] Bi-module clamps are primarily used for securement of the sidesof adjacent objects such as two solar panel modules.

[0043] A module is a set of photovoltaic cells while a solar panel is aplurality of modules. End clamps would secure the sides of a solarpanel. In any case, bi-module clamps are used to secure the sides of twoadjoining solar modules to an adjacent horizontal member.

[0044] Each horizontal member uses a pair of end clamps for securementof an object therebetween such as a solar panel. Each end clamp has asection or end referred to as a lip and preferably has a slight rise orheel on its bottom surface distally positioned from the lip end. The liphas a bottom surface that can be described as a gripping surface forengaging an object.

[0045] The slight rise or heel provides functional advantages whensecuring an object to a horizontal member. First, the slight riseprevents twisting of the end clamp while it is being bolted or securedinto position on the horizontal member. Second, when the grippingsurface of the lip engages an object, the rise forces the clamp inwardat 90 degrees to fully engage the object.

[0046] In the case of a solar panel, this design prevents the end clampfrom inadvertently separating the module frame from its glass. Also, therise provides spring tension against the module frame, providing fullengagement as the module laminate glass and frame flex under-extremestresses caused by weather conditions such as high wind and snow.

[0047] Besides an end clamp having a raised heel portion as describedabove, an alternative heel means for facilitating the securement of anobject between two end clamps can be by more than one piece performingthe same function such as a wedge or half-moon shaped washer positionedbetween an end clamp having no heel and the adjacent horizontal member.The purpose of the wedge or washer would be to angle the end clamp thesame as if the end clamp had a raised heel portion. However, the singleunitized piece is the preferred embodiment.

[0048] The heel design incorporated into the end clamp can be of anylength or shape. It does not have to be continuous across the extrusionso long as it can function to place inward pressure against an object tobe secured between an end clamp and another end clamp or bi-moduleclamp.

[0049] As stated earlier, the securing means, besides using a pair ofend clamps having respective heels, can also employ a heel means locatedbetween each end clamp not having a heel and the horizontal member. Theheel means can be, but should not be considered limited to, the use of awedge or half-moon shaped washer or other protrusion that, whenpositioned between the bottom side of the end clamp and the top surfaceof the horizontal member, will provide the same inward force against theobject when tightened to the horizontal support rail.

[0050] The support system includes the horizontal members, slidableinserts or T-nuts, end clamps, optional bi-module clamps and theattachment means.

BRIEF DESCRIPTION OF DRAWINGS

[0051]FIG. 1 is a perspective view and illustrates the position of thebase section of the roof mount above a rafter and a drill positioned fordrilling a pilot hole.

[0052]FIG. 2 is a view taken along line 2-2 of FIG. 1 and which shows adrilled pilot hole.

[0053]FIG. 3 indicates the roof mount displaced so that the pilot holeis in alignment with the support channel.

[0054]FIG. 4 is an exploded view showing the lag bolt and stanchionrelationship to the roof mount.

[0055]FIG. 5 is a perspective view when the lag bolt and stanchion areassembled to the roof mount.

[0056]FIG. 6 is a view taken along line 6-6 of FIG. 5.

[0057]FIG. 7 is a perspective view illustrating the relationship of theassembled roof mount to flashing material.

[0058]FIG. 8 is a perspective view of the package comprising a pair ofelongated C-shaped members and associated equipment.

[0059]FIG. 9 is a view taken along line 9-9 of FIG. 8.

[0060]FIG. 9a is a end view of an elongated U-shape member depicting alinear positioning groove for a drill bit to make a hole.

[0061]FIG. 10 is a perspective view illustrating the attachment of anelongated C-shaped member to a plurality of stanchions.

[0062]FIG. 11 is a perspective view illustrating the slidablerelationship of clamps relative to the C-shaped member and thepositioning of a solar module.

[0063]FIG. 12 is an exploded view of the relationship of an end clamp toa slidable insert.

[0064]FIG. 13 is an exploded view of the relationship of a bi-moduleclamp to a slidable insert.

[0065]FIG. 14 is a perspective view of an assembled solar panel having 4modules.

[0066]FIG. 15 is a side view showing a secured end clamp in relationshipto the side of a solar panel.

[0067]FIG. 16 is a view taken along line 16-16 of FIG. 15.

[0068]FIG. 17 is a side view showing a secured bi-module clamp inrelationship to the adjacent sides of two solar modules.

[0069]FIG. 18 is a view taken along line 18-18 of FIG. 17.

[0070]FIG. 19 is a perspective partial view of installation of an objectand mounting equipment upon an existing roof utilizing the end clamp ofmy invention.

[0071]FIG. 20 is a perspective partial view of installation of an objectand mounting equipment upon pipe supports.

[0072]FIG. 21 is a first alternative end clamp to that shown in FIG. 12.

[0073]FIG. 22 is a second alternative end clamp to that shown in FIG.12.

[0074]FIG. 23 is an alternative clamping means utilizing a wedge.

[0075]FIG. 24 is a first alternative design of a slidable insert to thatshown in FIG. 12.

[0076]FIG. 25 is an alternative means for providing a threaded member tothat shown in FIG. 24.

DETAILED DESCRIPTION

[0077]FIG. 1 through FIG. 6 illustrate the sequence for installing myroof mount to a rafter.

[0078]FIG. 1 illustrates the general relationship of base section 17 toa roof having decking 12 and rafter 14.

[0079] Base section 17 comprises a base 16 and a cylindrical member 18integral with and extending away from base 16. Cylindrical member 18 hasan offset wall area.

[0080] As illustrated in FIG. 2, base section 17 has a guide tunnel 20which extends from the top of cylindrical member 18 to the bottom ofbase 16. The purpose of guide tunnel 20 is to provide perpendicularalignment of drill bit 24 to rafter 14 for the drilling of pilot hole26. Perpendicular alignment is important because it minimizes theprobability of rafter splits, as can occur when a pilot hole is drilledwhich is not in perpendicular alignment to the rafter.

[0081] Cylindrical member 18 further has a cavity 22, the top of cavity22 defining an insertion opening 28. The walls of cavity 22 are threadedfor engaging a stanchion 42 as will be discussed later.

[0082] Defining the bottom of cavity 22 is top surface 30. A hole 32extends from top surface 30 through base 16. Hole 32 has a common axisof symmetry with cavity 22 and is designed to accept the stem 36 of afastening bolt 34 as shown in FIG. 4.

[0083] With the alignment as shown in FIG. 1, drill bit 24 is insertedinto guide tunnel 20 and a pilot hole 26 is drilled into rafter 14 asshown in FIG. 2.

[0084] Base section 17 is then displaced along decking 12 until pilothole 26 is aligned with hole 32 as shown in FIG. 3.

[0085]FIG. 4 illustrates the relationship of fastening bolt 34 andstanchion 42 to base section 17. Once hole 32 is aligned with pilot hole26, fastening bolt 34 is inserted through washer 40 and screwed intorafter 14. Fastening bolt head 38 remains within cavity 22. Stanchion 42has a male threaded end 44 and is inserted through insertion opening 28for threadable engagement within cavity 22.

[0086] Distal from threaded end 44 is female threaded end 46 forfrictional engagement of mounting bolt 48 and washer 50. FIG. 5 and FIG.6 illustrate the assembled roof mount 10 fastened to rafter 14. Roofmount 10 comprises base section 17, stanchion 42 along with threadablyconnected mounting bolt 40 and washer 50.

[0087] In practice, the rafters 14 and decking 12 will be installedprior to the installation of roof mount 10. A single pilot hole 26 isdrilled for each roof mount which, due to my design, will beperpendicular to the roof rafter and minimize the risk of rafter split.The number of roof mounts used will be determined by the size of theobject to be mounted.

[0088] Once the pilot hole is drilled, base section 17 is slid a shortdistance and fastening bolt 34 is inserted to fasten base section torafter 14. Again, because only one hole is drilled into the rafter foreach roof mount 10, less labor time is required than with typical floorflanges.

[0089] Once all roof mounts 10 have been fastened to their respectiverafters, flashing 52 must be installed to protect the roof from the riskof future water damage. FIG. 7 illustrates the arrangement of multipleflashings 52 over a plurality of roof mounts 10. Following flashinginstallation, the decking 12 is typically layered with roofing material(not shown).

[0090] Although my mounting system can be utilized for a variety ofobjects to be mounted above a roof, the following procedure will addressinstallation of a solar panel having multiple modules.

[0091] Once the roof is in a condition for installing a solar panel, apair of C-shaped elongated horizontal members 54 are provided. Eachhorizontal member 54 has a base wall 56 and a pair of side walls 58 and60. A linear groove 62 runs along the bottom surface of base wall 56 ascan be seen in FIG. 9a and FIG. 10.

[0092]FIG. 9a also illustrates a pair of horizontal ledges 64 and 66extending inward from sidewalls 58 and 60 toward each other. Theseledges extend the length of sidewalls 58 and 60. A pair of protrudinglips 68 and 70 extend inward from the distal end of sidewalls 58 and 60relative to base wall 56. A track area is defined by the surface area ofledges 64 and 66 which face lips 68 and 70 respectively. The purpose ofthe track will be discussed below.

[0093]FIG. 10 illustrates the attachment of horizontal members 54 toroof mounts 10. Initially, mounting bolts 48 and washers 50 are removedfrom stanchions 42. Horizontal member 54 is positioned along eachflashing cone. As shown in FIG. 9a, a drill is used to drill mountingholes 72 along groove 62 on base wall 56 for each roof mount. Once thefirst mounting hole 72 is drilled, additional mounting holes can bedrilled by simply measuring the distance from the last hole drilled whenthe spacing between the rafters is known.

[0094] The support means can also be modified to be fastened to anexisting roof by use of base mounts 810 as shown in FIG. 19. Theattachment means comprises base mount 810 which joins to member 54. Aninsert is used to threadably sandwich member 54 between the insert andbase mount 810 for additional structural support. Alternatively, basemount 810 can be directly bolted to member 54 but this configurationwould not provide the structural support as if base mount 810 werebolted to the insert.

[0095] The support means can also be modified to be fastened to groundraking system 700 as shown in FIG. 20. The attachment means comprises aU-shaped member 710 which joins to member 54 having a pipe membertherebetween. The ends of U-shaped member 710 are operatively attachedto member 54 by the use of an insert (not shown) which essentiallyserves as the base mount although located within member 54.Alternatively, U-shaped member 710 can be directly bolted to member 54but this configuration would not provide the structural support as ifU-shaped member 710 were bolted to the insert.

[0096] Once all mounting holes 72 have been drilled, horizontal member54, is positioned the above flashing cones with mounting holes 72aligned with female threaded end 46. Mounting bolts 48 and washers 50are then used to frictionally engage horizontal members 54 to respectiveroof mounts 10. FIG. 11 shows horizontal members 54 assembled to roofmounts 10.

[0097] At least two slidable inserts 74 are provided for each horizontalmember 54 and a general configuration is illustrated in FIG. 12 and FIG.13. Insert 74 has a female threaded hole 80. The outer configuration ofinsert 74 is designed to be slidably received within track area ofhorizontal member 54. The required number of inserts 74 is dependentupon the number of clamps needed to secure the solar panel. There aretwo types of clamps available: end clamps 76 and bi-module clamps 78.

[0098] End clamp 76 is illustrated in FIG. 12 and has a hole 82 foralignment with threaded hole 80 on insert 74. End clamp 76 has a notchedsurface 84 for frictionally engaging the solar panel and securing itbetween notched surface 84 and horizontal member 54 when end clamp bolt86 has its threaded stem 88 passed through washer 90 and hole 82 forengagement with threaded hole 80 on insert 74. FIG. 15 and FIG. 16 showthe solar panel in frictional engagement between notched surface 84 andhorizontal member 54.

[0099] Two end clamps 76 are used to secure a solar panel therebetweenand along each horizontal member 54 when each end clamp 76 is threadablyfastened to insert 74 using bolt 86. A solar panel is defined as atleast one solar module and can be a number of modules in series asillustrated in FIG. 14. Therefore, four end clamps 76 are used to securea solar panel to two horizontal members 54.

[0100] A bi-module clamp 78 is illustrated FIG. 13. They are used tosecure the sides of two adjoining solar panel modules and to ahorizontal member 54 when bi-module clamp 78 is threadably fastened toinsert 74 using a bolt 104. The use of bi-module clamps 78 and endclamps 76 in my mounting system is best illustrated in FIG. 14.

[0101] The number of bi-module clamps required for each horizontalmember 54 is determined by the formula:

[0102] number of bi-module clamps=(number of modules −1).

[0103] Each bi-module clamp 78 has a top side 92, a bottom side 94, apair of side walls 96. Holes 98 located on top side 92 and bottom side94 have a common axis of symmetry and are for alignment with threadedhole 80 on insert 74. Top side 92 extends perpendicularly away from sidewalls 96 in either direction forming overhangs 100 having notchedsurfaces 102. Notched surfaces 102 are for frictionally engaging thesolar module and securing it between notched surface 102 and horizontalmember 54 when bolt 104 has its threaded stem 106 passed through washer90 and holes 98 for engagement with threaded hole 80 on insert 74. FIG.17 and FIG. 18 show a pair of solar modules in frictional engagementbetween notched surfaces 102 and horizontal member 54.

[0104] As a slidable insert 74 is threadably engaged and frictionallypositions either bi-module clamp 78 or end clamp 76 along member 54,insert 74 also frictionally engages an area of member 54. Thisrelationship is illustrated in FIG. 16 and FIG. 18. This engagementchanges the structural properties of member 54 to that of a structuralsquare for enhanced strength. In addition, when engaged to the module orsolar panel frame, the structural properties of the module frame combinewith horizontal member 54 and form a rigid inter-locking trussedcross-section.

[0105] Alternatives to that shown in FIG. 12 are shown in FIG. 24 andFIG. 25. Rather than having a bolt with a threaded stem which threadsdownward into insert 74, FIG. 24 shows a slidable insert 274 having anupward rising threaded stem 288. FIG. 25 shows insert 74 where bolt 390having male stem 388 is screwed into from below to have the same finalconfiguration as that shown in FIG. 24.

[0106] Each end clamp 76 has a heal means, or slight rise 108 on itsbottom surface distally positioned from its clamping surface and isillustrated in FIG. 12 and FIG. 15. Rise 108 prevents end clamp 76 fromtwisting while fastening bolt 86 to insert 74.

[0107] Alternative designs to end clamp 76 shown in FIG. 12 arepresented in FIG. 21 and FIG. 22. Rather than having an aperture locatedon the portion of the clamp which contacts member 54 as is the case forclamp 76, apertures 172 and 272 for end clamps 176 and 276 shownrespectively in FIG. 21 and FIG. 22 are located on the horizontalportion which includes notched surface 184 and 284. Alternative endclamps 176 and 276 also incorporate a heel means, or raised heels 186and 286 respectively.

[0108] Besides the heel means of the end clamp designs mentioned whichincorporate a heel, an alternative heel means, which performs the samefunction as a unitized heel, i.e. preventing the twisting of the endclamp while being secured to horizontal member 54 and forcing the clampinward at 90 degrees to fully engage the object by the notched surfacecan be accomplished with the combination shown in FIG. 23. Here, endclamp 376 can be the same design as for end clamp 76 but excluding heelportion 108. The function of the heel is performed by a second item,denoted as wedge 386. The width of wedge 386 must be sufficient so itwill contact both top sides of member 54. Alternatively, a pair ofsmaller wedges can be positioned on each top side of member 54 directlybelow end clamp 376 to provide the proper inward angle toward the objectto grip.

[0109] As stated earlier, the securing means, besides being an end clamphaving a heel, can also be an end clamp not having a heel used incombination with a wedge or half-moon shaped washer or other protrusionthat, when positioned between the bottom side of the end clamp and thetop surface of the horizontal member, will provide the same inward forceagainst the object when tightened to the horizontal support rail.

[0110] As best illustrated in FIG. 14, horizontal members 54 along withthe associated component parts, namely slidable inserts 74, end clamps76 and bi-module clamps 78 and the attachment means to roof mount 10comprise a solar panel support structure.

[0111]FIG. 8 illustrates the unitized packaging for the mountingcomponents, namely a pair of horizontal members 54 and the associatednumber of inserts 74, bi-module clamps 78, and a pair of end clamps 76.The ends of the horizontal members 54 are secured by tape or otherpackaging material 110. Packaging material 110 not only maintains therelationship of horizontal members 54 to one another, it also preventsthe inserts and clamps from escaping.

[0112] As can be best seen in FIG. 9a, the outward facing surface 112 ofthe open side of horizontal member 54 has ridges. These ridges extendthe length of each member 54 and form mating or interlocking surfaceswhen the open sides of two horizontal members 54 are aligned andcontacted with one another. FIG. 9 illustrates two horizontal members 54mated to one another and show a bi-module clamp 78 and an end clamp 76in view.

[0113] During assembly, the inserts and clamps are placed into ahorizontal member 54. Packing such as paper (not shown) is also insertedto prevent the inserts and clamps from excessive movement and potentialwear and damage. The second horizontal member 54 is thereafter mated tothe other member by cooperatively engaging along surfaces 112. Outsidepackaging is thereafter used to seal the open ends.

I claim:
 1. A mounting system for mounting an object above a roof havingflashing and fastened to at least one roof rafter, said mounting systemcomprising: a) at least one roof mount for fastening to a respectiveroof rafter, each roof mount comprising: a base and an integrated hollowcylinder, said cylinder having an offset wall and an insertion openingpointing away from the roof; an alignment means for ensuring that apilot hole drilled into a rafter will be drilled at a perpendicularangle to the rafter; and a means for fastening the base to a rafter; b)at least one stanchion having a top end and a bottom end, said bottomend being fitted into a respective insertion opening of a base section,thereby orientating said stanchion away from the roof, each of saidstanchions being of sufficient length to extend at least to the top ofthe flashing material; c) support means for an object; said supportmeans positioned upon at least one stanchion; and d) means to attachsaid support means to at least one stanchion.
 2. The mounting system ofclaim 1 wherein said alignment means is a guide tunnel formed in saidoffset wall and said base whereby said guide tunnel can receive a drillbit for drilling a pilot hole into a rafter.
 3. The mounting system ofclaim 1 wherein said means for fastening comprises a hole extending fromthe hollow cylinder through said base so that a single lag bolt may bereceived through said insertion opening and fasten a base to a roofrafter.
 4. The mounting system of claim 1 wherein said support meanscomprises at least one horizontal support member and a respective pairof end clamps slidably connected to each said horizontal support member,where an object, once positioned upon said horizontal support member, isthereafter secured to said horizontal support member by the use of saidpair of end clamps.
 5. The mounting system of claim 1 wherein said meansto attach said support means comprises threadably engaging the supportmeans to the top end of at least one of said stanchions.
 6. The mountingsystem of claim 2 wherein said means for fastening comprises a holeextending from the hollow cylinder through said base so that a singlelag bolt may be received through said insertion opening and fasten abase to a roof rafter.
 7. The mounting system of claim 2 wherein saidsupport means comprises a pair of horizontal support members and aplurality of clamps slidably connected to said horizontal supportmembers, where an object once positioned upon said pair of horizontalsupport members is thereafter secured by the use of said clamps.
 8. Themounting system of claim 2 wherein said means to attach said supportmeans comprises threadably engaging the support means to the top end ofa pair of said stanchions.
 9. The mounting system of claim 3 whereinsaid support means comprises a pair of horizontal support members and aplurality of clamps slidably connected to said horizontal supportmembers, where an object once positioned upon said pair of horizontalsupport members is thereafter secured by the use of said clamps.
 10. Themounting system of claim 3 wherein said means to attach said supportmeans comprises threadably engaging the support means to the top end ofa pair of said stanchions.
 11. A support for supporting an object whichis mounted above ground comprising: a pair of extruded horizontalmembers; each horizontal member having a track; at least two inserts foreach horizontal member, each of said inserts adapted for slidablemovement within the track of said horizontal member and each of saidinserts having an aperture; and, a pair of end clamps for eachhorizontal member, each of said end clamps having an aperture forallowing the threaded stem of a bolt to pass through, said end clampscapable of being positioned for securing an object therebetween whensaid pair of end clamps are secured to a respective insert when saidinsert is within the track of said horizontal member; and, means forattaching said pair of horizontal members to a fixture.
 12. The supportof claim 11 where said means for attaching comprises the attachment ofsaid horizontal members to a plurality of base mounts secured torespective roof rafters.
 13. The support of claim 11 where said meansfor attaching comprises U-shaped members operatively attaching ahorizontal member to a pipe support.
 14. A unitized end clampcomprising: a base section; a lip section, said lip section extendingsubstantially horizontally away from said base section, said lip sectionhaving a bottom surface for frictional engagement; an aperture extendingthrough said base section in perpendicular relation to said bottomsurface of said lip section; and, a heel section distally located fromsaid lip section, said heel section extending downward from said basesection on the side opposite of said aperture from said lip section. 15.A method for securing an object upon mounting equipment for supportabove the ground, comprising the steps of: providing at least onehorizontal member upon which the weight of the object will be supported;providing a pair of end clamps for each respective horizontal member,each said end clamp having a lip end, a vertical orientated apertureused to secure an end clamp to said horizontal member while frictionallyengaging a portion of an object with said lip end; providing a heelmeans between a portion of said end clamp and said respective horizontalmember, where said heel means function is to, while said end clamp isbeing operatively secured to a horizontal member, prevent said end clampfrom rotation and to enhance the frictional contact between the lip endand an object by orientating the lip end inward at 90 degrees to fullyengage the object. securing said object between said end clamps byinserting a threaded stem through said aperture where said stem isoperatively secured on one side to said horizontal member and on theother side by either a bolt head or nut where the object is securedbetween the end clamps in response to the tightening of the nut or bolt.16. The heal means of claim 15 which is said end clamp furthercomprising a heel section extending downward and distally located onsaid end clamp from said lip end.
 17. The heal means of claim 15 whichis an item sized to be positioned between a respective end clamp andsaid horizontal member, said object further being positioned on the sideof said aperture opposite from said lip end.
 18. The item of claim 17,said item being a wedge.
 19. The item of claim 17, said item being ahalf-moon washer.